Hollow hanging rod of a hanger assembly for ceiling fan

ABSTRACT

A hollow hanging rod includes a tubular section having an axial hole extending through a top open-end thereof, and a bowl-shaped section extending upwardly, curvedly, and expandedly from the top open-end of the tubular section and having a top open-end distal from the top open-end of the tubular section, a bottom open-end connected to the top open-end of the tubular section, and a surrounding wall connected between the top and bottom open-ends of the bowl-shaped section and defining an interior space with a width that gradually increases from the bottom to the top open-ends of the bowl-shaped section. The top open-end of the bowl-shaped section defines a single top opening having a width larger than that of the axial hole. The interior space opens at the single top opening. The tubular and bowl-shaped sections are made of metal, and are formed integrally as a one-piece body.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority of Taiwanese Application No. 097209545, filed on May 30, 2008.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a hanging rod, more particularly to a hollow hanging rod of a hanger assembly for a ceiling fan.

2. Description of the Related Art

Referring to FIGS. 1 and 2, a conventional hanging rod 100 suitable for connection with a ceiling fan usually cooperates with a fixed seat 101 and a canopy 102. The hanging rod 100 includes a bowl-shaped section 11, a tubular section 12 extending into the center of the bowl-shaped section 11, a supporting rod 13 extending through the bowl-shaped section 11 and the tubular section 12, and a bolt 14 engaged threadedly to the bowl-shaped section 11 and the tubular section 12. The supporting rod 13 strengthens the supporting force of the bowl-shaped section 11 on the tubular section 12. The bolt 14 is used to connect fixedly the bowl-shaped section 11 and the tubular section 12. However, in actual practice, the conventional hanging rod 100 has the following drawbacks:

1. Since the conventional hanging rod 100 makes use of the supporting rod 13 and the bolt 14 to connect fixedly the bowl-shaped section 11 and the tubular section 12, if the bolt 14 is not screwed tightly or if the bolt 14 becomes structurally weak after a long period of use, the ceiling fan is likely to shake unsteadily and violently during operation, even to the extent that it might fall off from the ceiling.

2. Since the bowl-shaped section 11 and the tubular section 12 are made separately, these two elements must be made precisely so that they fit together snugly. Hence, the making of the conventional hanging rod 100 is complicated, and the manufacturing cost thereof is increased.

3. Since the conventional hanging rod 100 has many components, assembly of the same is time-consuming. Also, mistakes are frequently made during assembly due to the many components.

4. The color and pattern of the bowl-shaped section 11 and the tubular section 12 cannot be made continuously uniform, thereby affecting the aesthetic appearance of the ceiling fan.

SUMMARY OF THE INVENTION

Therefore, the object of the present invention is to provide a hollow hanging rod that is capable of overcoming the aforementioned drawbacks of the prior art.

According to one aspect of this invention, a hollow hanging rod of a hanger assembly for a ceiling fan comprises a tubular section having a top open-end and an axial hole extending through the top open-end, and a bowl-shaped section extending upwardly, curvedly, and expandedly from the top open-end of the tubular section and having a top open-end distal from the top open-end of the tubular section, a bottom open-end connected to the top open-end of the tubular section, and a surrounding wall connected between the top and bottom open-ends of the bowl-shaped section and defining an interior space with a width that gradually increases from the bottom open-end of the bowl-shaped section to the top open-end of the bowl-shaped section. The top open-end of the bowl-shaped section defines a single top opening having a width larger than that of the axial hole. The interior space opens at the single top opening. The tubular section and the bowl-shaped section are made of metal, and are formed integrally as a one-piece body.

According to another aspect of this invention, a hollow hanging rod of a hanger assembly for a ceiling fan comprises a tubular section having a top open-end and an axial hole extending through the top open-end, and a bowl-shaped section extending upwardly, curvedly, and expandedly from the top open-end of the tubular section and having a top open-end distal from the top open-end of the tubular section, a bottom open-end connected to the top open-end of the tubular section, and a surrounding wall connected between the top and bottom open-ends of the bowl-shaped section and defining an interior space with a width that gradually increases from the bottom open-end of the bowl-shaped section to the top open-end of the bowl-shaped section. The top open-end of the bowl-shaped section defines a single top opening having a width larger than that of the axial hole. The interior space opens at the single top opening. The tubular section and the bowl-shaped section are made of metal, and are formed integrally as a one-piece body. The hanging rod is made by a method which includes the steps of: (a) preparing a metal tube; and (b) partially expanding the metal tube to form the bowl-shaped section.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiments of the invention, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a conventional hanging rod, a fixed seat, and a canopy;

FIG. 2 is a top schematic view of the conventional hanging rod;

FIG. 3 is a fragmentary perspective view of a hollow hanging rod according to the first preferred embodiment of the present invention;

FIG. 4 is a fragmentary sectional view of the first preferred embodiment;

FIG. 5 is an exploded perspective of a hollow hanging rod according to the second preferred embodiment of the present invention;

FIG. 6 is a sectional view of the second preferred embodiment in an assembled state; and

FIG. 7 is a sectional view of the second preferred embodiment taken along line VII-VII of FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before the present invention is described in greater detail, it should be noted that the same reference numerals have been used to denote like elements throughout the specification.

Referring to FIGS. 3 and 4, a hollow hanging rod 200 according to the first preferred embodiment of the present invention is shown to comprise a bowl-shaped section 20 and a tubular section 30.

The bowl-shaped section 20 has a top open-end 21 defining a single top opening 210 having a width (W1), a bottom open-end 25, and a surrounding wall 26 connected between the top and bottom open-ends 21, 25. The surrounding wall 26 defines an interior space 261 with a width that gradually increases from the bottom open-end 25 to the top open-end 21, and has inner and outer surfaces. The interior space 261 opens at the single top opening 210. In this embodiment, a positioning slot 22 extends through the inner and outer surfaces of the surrounding wall 26, and extends curvedly and downwardly from the top open-end 21 to the bottom open-end 25. The positioning slot 22 is used for receiving and positioning a protrusion 90 of a fixed seat 900. When the bowl-shaped section 20 has a substantial thickness, the positioning slot 22 may be replaced by a positioning groove that opens at the outer surface of the surrounding wall 26.

The tubular section 30 has a top open-end 33 distal from the top open-end 21 and connected to the bottom open-end 25 of the bowl-shaped section 20, a bottom open-end (not shown), and an axial hole 40 extending through the top open-end 33 and communicating with the interior space 261. The axial hole 40 has a width (W2) smaller than the width (W1) of the single top opening 210. The bowl-shaped section 20 extends upwardly, curvedly, and expandedly from the top open-end 33 of the tubular section 20. The tubular section 30 and the bowl-shaped section 20 are made of metal, and are formed integrally as a one-piece body. The tubular section 30 may have a width that converges downwardly from the top open-end 33 thereof in an alternative embodiment.

The hanging rod 200 is made by a method which includes the steps of: (a) preparing a metal tube; and (b) partially expanding the metal tube to form the bowl-shaped section 20. The metal tube may be expanded by a cold-working process. In this embodiment, the metal tube is expanded by inserting a middle part thereof into a ball-shaped cavity of a mold (not shown) with two opposite end portions thereof being disposed externally of the mold. A high-pressure hydraulic fluid, such as oil, is introduced into the middle part of the metal tube so as to expand the middle part of the metal tube, thereby forming a ball-shaped middle part. Afterwards, the ball-shaped middle part of the metal tube is removed from the mold, and is cut into halves to obtain two bowl-shaped sections 20, each of which is integral with one of the end portions of the metal tube. The end portions of the metal tube form the tubular sections 30 of the hanging rod 200. Hence, two hanging rods 200 can be obtained from this process.

Since the bowl-shaped section 20 and the tubular section 30 are integrally formed into one body, the manufacturing cost is reduced to a great extent because it is not necessary to purchase separately the supporting rod 13 and the bolt 14 (see FIGS. 1 and 2). An aesthetic appearance of the hanging rod 200 is also improved. Further, since it is not necessary to assemble components during use of the hanging rod 200, there is no possibility that mistakes will be made during assembly of the hanging rod 200 and the ceiling fan. Hence, the hanging rod 200 of the present invention is safe and convenient to use, has a manufacturing cost that is minimized, and has an enhanced appearance.

Referring to FIGS. 5 to 7, a hanging rod 200′ according to the second preferred embodiment of the present invention is shown to be similar to the first preferred embodiment. However, in this embodiment, the surrounding wall 26′ of the bowl-shaped section 20′ has a corrugated structure, and includes a plurality of alternating protrusions 24 and indentations 24′ formed around the surrounding wall 26 and extending from the top open-end 21′ to the bottom open-end 25′. The surrounding wall 26′ is formed with a positioning groove 23 instead of the positioning slot 22 (see FIG. 3). The positioning groove 23 opens at the outer surface of the surrounding wall 26′, and extends curvedly and downwardly from the top open-end 21′ to the bottom open-end 25′.

The tubular section 30′ in this embodiment includes a bottom engaging part 31 tapering downwardly to the bottom open-end 34′, and a projection 32 projecting from an inner surface of the bottom engaging part 31 toward the axial hole 40 and tapering upwardly from the bottom open-end 34′.

The hanging rod 200′ further comprises an extension rod 50 having an upper engaging part 51 fitted into the bottom engaging part 31 and extending downwardly and outwardly from the bottom open-end 34′, an indentation 52 indenting from an outer surface of the upper engaging part 51 and receiving fittingly the projection 32, and a lower fixing portion 53 disposed below the upper engaging part 51 and externally of the tubular section 30′ and adapted to be connected with the ceiling fan. When the projection 32 and the indentation 52 are engaged with each other, the extension rod 50 cannot rotate relative to the tubular section 30′. Further, through the tapering structure of the upper and bottom engaging parts 51, 31, the extension rod 50 is prevented from separating from the tubular section 30′. The lower fixing portion 53, in this embodiment, is formed with an external thread. Alternatively, the lower fixing portion 53 may be formed with an insert hole to receive an insert pin.

The positioning groove 23, the protrusions 24, and the indentations 24′ may be formed by employing the above-mentioned method in combination with a suitable mold. The bottom engaging part 31, the projection 32, the upper engaging part 51, and the indentation 52 may be formed by a cold-working process. On the other hand, while the tubular section 30′ is tapered only at the bottom engaging part 31 in this embodiment, the tapering structure of the tubular section 30′ may be elongated to extend from the top open-end 33′ to the bottom open-end 34′ thereof. Similarly, while the extension rod 50 is tapered only at the upper engaging part 51, the tapering structure of the extension rod 50 may be elongated to extend from a top end to a bottom end thereof.

Through the presence of the extension rod 50, the length of the tubular section 30′ may be increased during installation. In this embodiment, the extension rod 50 has a fixed length. In actual application, the length of the extension rod 50 may be varied depending on installation requirements.

While the present invention has been described in connection with what are considered the most practical and preferred embodiments, it is understood that this invention is not limited to the disclosed embodiments but is intended to cover various arrangements included within the spirit and scope of the broadest interpretations and equivalent arrangements. 

1. A hollow hanging rod of a hanger assembly for a ceiling fan, comprising: a tubular section having a top open-end and an axial hole extending through said top open-end; and a bowl-shaped section extending upwardly, curvedly, and expandedly from said top open-end of said tubular section and having a top open-end distal from said top open-end of said tubular section, a bottom open-end connected to said top open-end of said tubular section, and a surrounding wall connected between said top and bottom open-ends of said bowl-shaped section and defining an interior space with a width that gradually increases from said bottom open-end of said bowl-shaped section to said top open-end of said bowl-shaped section; said top open-end of said bowl-shaped section defining a single top opening having a width larger than that of said axial hole; said interior space opening at said single top opening; and said tubular section and said bowl-shaped section being made of metal and being formed integrally as a one-piece body.
 2. The hanging rod of claim 1, wherein said surrounding wall has inner and outer surfaces, said bowl-shaped section further having a positioning slot provided in said surrounding wall, said positioning slot extending through said inner and outer surfaces of said surrounding wall and extending curvedly and downwardly from said top open-end of said bowl-shaped section toward said bottom open-end of said bowl-shaped section.
 3. The hanging rod of claim 1, wherein said surrounding wall has inner and outer surfaces, said bowl-shaped section further having a positioning groove provided in said surrounding wall, said positioning groove opening at said outer surface and extending curvedly and downwardly from said top open-end of said bowl-shaped section toward said bottom open-end of said bowl-shaped section.
 4. The hanging rod of claim 1, wherein said surrounding wall has a corrugated structure, and includes a plurality of alternating protrusions and indentations provided on said surrounding wall and extending from said top open-end of said bowl-shaped section to said bottom open-end of said bowl-shaped section.
 5. The hanging rod of claim 1, wherein said tubular section further has a bottom open-end, and a bottom engaging part tapering downwardly to said bottom open-end, said hanging rod further comprising an extension rod that has an upper engaging part fitted into said bottom engaging part and that extends downwardly and outwardly from said bottom open-end of said tubular section.
 6. The hanging rod of claim 5, wherein said tubular section further has a projection projecting from an inner surface of said bottom engaging part toward said axial hole and tapering upwardly from said bottom open-end of said tubular section, said extension rod further having an indentation indenting from an outer surface of said upper engaging part and receiving fittingly said projection.
 7. The hanging rod of claim 6, wherein said extension rod further has a lower fixing portion disposed below said upper engaging part and externally of said tubular section and adapted to be connected with the ceiling fan.
 8. A hollow hanging rod of a hanger assembly for a ceiling fan, comprising: a tubular section having a top open-end and an axial hole extending through said top open-end; and a bowl-shaped section extending upwardly, curvedly, and expandedly from said top open-end of said tubular section and having a top open-end distal from said top open-end of said tubular section, a bottom open-end connected to said top open-end of said tubular section, and a surrounding wall connected between said top and bottom open-ends of said bowl-shaped section and defining an interior space with a width that gradually increases from said bottom open-end of said bowl-shaped section to said top open-end of said bowl-shaped section; said top open-end of said bowl-shaped section defining a single top opening having a width larger than that of said axial hole; said interior space opening at said single top opening; said tubular section and said bowl-shaped section being made of metal and being formed integrally as a one-piece body; and said hanging rod being made by a method which includes the steps of: (a) preparing a metal tube; and (b) partially expanding said metal tube to form said bowl-shaped section.
 9. The hanging rod of claim 8, wherein step (b) includes: inserting a middle part of said metal tube into a ball-shaped cavity of a mold with two opposite end portions thereof being disposed externally of the mold; expanding said middle part by introducing a high-pressure hydraulic fluid into said middle part to form a ball-shaped middle part; cutting said ball-shaped middle part into halves to obtain two said bowl-shaped sections, each of which is integral with one of said end portions. 